JP2005529657A - Consumer scrubbing wipe article and method of manufacturing the same - Google Patents

Abstract

A consumer scrubbing wipe article comprising a nonwoven substrate and a texture layer. The nonwoven substrate has a dry basis weight of less than about 300 g / m ² , thus facilitating easy and comfortable handling by the user. The texture layer is a non-crosslinked abrasive resin base material that is printed onto at least one surface of the nonwoven substrate. In doing so, the texture layer covers less than the entire surface of the substrate and extends outwardly by at least 50 microns beyond the substrate surface on which it is printed. This property ensures that the scrubbing wipe article has unique scrubbing properties.

Description

  The present invention relates to consumer scrubbing wipe articles. More specifically, it relates to a nonwoven substrate-based scrubbing wipe article that has an enhanced scrubbing capability and has a printed texture layer that is amenable to substrate loading with various chemical solutions.

  Consumers have long enjoyed the convenience of disposable nonwoven base wipes or wiping articles to clean various surfaces around the home. One common example is a paper towel. More recently, wipes loaded with cleaning or disinfecting / disinfecting chemicals have become increasingly popular. These products are useful not only to remove dirt from the surface, but also to disinfect the contact surface to some extent. As a general rule, typical loaded wipe products (ie, non-woven substrates with liquid or dry chemicals absorbed into the non-woven substrate) will have a resin bonded to add strength when wet. Nonwoven substrates composed of certain short fibers are included. These resins are usually anionic in nature. However, since the cleaning / disinfecting / disinfecting solutions used primarily for loaded wipes are cationic quaternary ammonium salts, the use of nonionic or cationic binder resins has tended to increase. Nonionic or cationic binder resins provide the most reliable release of quaternary ammonium salts from the substrate. Quaternary ammonium salts serve as effective antibacterial agents, but certain potential disadvantages such as obvious drying of the user's hand after repeated use and lack of compatibility with other chemicals and substrates Has been identified.

  Beyond the disadvantages of identified cleaning solutions, disinfecting wipes cannot address additional consumer preferences. That is, consumers often want to use wipes for cleaning tasks that require scrubbing or scraping. For example, it is difficult, if not impossible, to remove dry food from a countertop using an inherently soft disinfecting wipe (or non-disinfecting wipe). Conversely, however, consumers are strongly fond of wiping not being too stiff for ease of use (in other words, wiping is draping) and minimizing damage to the user's hands, etc. . As such, for many applications, commercially available scraping pads are not easily acceptable.

  Attempts to address the concerns identified above have faced limited success. In general terms, currently available consumer wipe products, which are referred to as having “scrubbyness” properties, generally comprise a nonwoven base substrate onto which thermoplastic fibers are meltblown. An example of this technique is described in US Pat. No. 4,659,609 issued to Lamers et al. Theoretically, meltblown fibers provide an abrasive textured surface for the resulting wipe. In practice, however, meltblown fibers are not only due to the randomness with which the fibers are distributed across the surface of the substrate, but mainly because of the very thin nature of blown fibers (typically less than 10 microns in diameter). Moreover, it is only slightly “abrasive” than the base substrate itself.

  Alternatively, U.S. Pat. No. 5,213,588 to Wong et al. Describes an abrasive wipe consisting of a nonwoven substrate printed thereon with a cured scrubbing bead mixture. Yes. Wong is focused on using a paper towel-like base substrate that may be less durable than other nonwoven materials. Nevertheless, the printability of the scrubbing layer facilitates the formation of practical texture patterns compared to meltblown fibers. Furthermore, Wong's scrubbing bead blend technology requires a relatively long manufacturing cycle due to the essential curing (or crosslinking) of the scrubbing bead blend resin. The mixture includes polymer abrasive particles having a diameter of 20 to 400 microns prior to printing. The printed mixture (otherwise containing particles) extends 40-300 microns beyond the surface of the substrate. Wong's wipe is believed to have obtained this raised pattern due to the large particles contained in the resin mixture. Finally, Wong's scrubbing bead mixture is anionic. This property clearly limits the types of chemical solutions that can be “loaded” into the wipe. In particular, Won's scrubbing wipes cannot be loaded with certain cationic aqueous cleaning agents such as quaternary ammonium salts. Conversely, other scrubbing wipe products incorporate a cationic resin nonwoven substrate and / or a texture layer that is cation-based and therefore cannot be loaded with anionic chemical solutions.

  Consumer demand for scrubbing wipe products continues to grow. Unfortunately, currently available wipe products do not provide an acceptable level of scrubiness, are limited in the types of chemical solutions that can be delivered, and / or require stringent manufacturing requirements. Therefore, there is a need for not only manufacturing methods, but also consumer scrubbing and wiping articles that have a high degree of scrubberiness, facilitate easy handling by the user, and can be loaded with a wide variety of chemical solutions. .

One aspect of the present invention relates to consumer scrubbing wipe articles. The article includes a nonwoven substrate and a texture layer. Nonwoven substrate having a dry basis weight of less than about 300 g / m ^2, thus promoting the easy and comfortable handling by the user. The texture layer is a non-crosslinked abrasive resin base material that is printed onto at least one surface of the nonwoven substrate. In this regard, the texture layer covers less than the entire substrate surface and extends outwardly by at least 50 microns beyond the substrate surface on which it is printed. This property ensures that the scrubbing wipe article has unique scrubbing properties that are different from other known lightweight nonwoven wipes. In a preferred embodiment, the texture layer comprises a resin that is characterized as independently providing scrubbing properties to the scrubbing wipe article when fused and bonded to the nonwoven substrate. In another preferred embodiment, the wiping article further comprises a chemical solution absorbed into the nonwoven substrate. In this regard, and in accordance with one more preferred embodiment, the chemical solution can be cationic, anionic, or neutral.

Another aspect of the invention relates to a method of manufacturing a consumer wipe article. The method includes providing a nonwoven substrate having a dry basis weight of less than about 300 g / m ² . An abrasive resin base matrix is also provided. The matrix is printed onto the surface of the nonwoven substrate to cover less than the entire surface. The printed matrix is then fused (eg, dried) to produce a texture layer that provides scrubberiness properties. In this connection, the texture layer is produced without cross-linking of the matrix resin. Once fused, the texture layer extends at least 50 microns outward beyond the substrate surface on which it is printed. In a preferred embodiment, the texture layers are fused by ambient temperature drying or exposure to infrared light / heat. In another preferred embodiment, the matrix is pattern printed onto the nonwoven substrate in a manner that produces a plurality of repeated discrete lines.

  A preferred embodiment of a consumer scrubbing wipe article 10 according to the present invention. As used throughout this specification, the term “consumer” relates to any household, industrial, hospital or food industry use of the article 10. In general terms, the article 10 comprises a nonwoven substrate 12 and a texture layer 14 (generally referenced in FIG. 1). As will become more apparent below, the nonwoven substrate 12 and the texture layer 14 can be made of a variety of different materials. In any event, the texture layer 14 is characterized as comprising an abrasive non-crosslinked resin and is printed onto the nonwoven substrate 12. In particular, and with additional reference to FIG. 2, the nonwoven substrate 12 defines first and second opposing surfaces 16,18. For purposes of illustration, the thickness of the substrate 12 and the texture layer 14 is exaggerated in FIG. The texture layer 14 is printed on one or both of the nonwoven substrate surfaces 16,18. In a preferred embodiment, the scrubbing wipe article 10 further comprises a chemical solution (not shown) loaded into or absorbed by the nonwoven substrate 12. The applicable chemical solutions are described in more detail below. However, among other things, the texture layer 14 is preferably configured to accommodate a wide variety of chemical solutions, including those that are neutral, cationic, or anionic. Further, the scrubbing wipe article 10 is equally useful without a chemical solution. In other words, the scrubbing properties provided by the scrubbing wipe article 10 cleans a large number of surfaces and provides the user with an increased scrubbing capability independently so that the chemical solution is not a required element of the present invention. To do.

  As well as processing of the nonwoven substrate 12 and texture layer 14, their preferred compositions are provided below. For this purpose, the scrubbing wipe article 10 is described as providing “scrubbiness” properties that are significantly improved over known lightweight consumer wipe products. The term “scrubbiness” relates to the ability to scrape or remove relatively small, undesirable items that otherwise adhere to the surface as the wipe is moved back and forth over the item. Not only by forming a hardened scrubbing material (ie, harder than the substrate itself) on the surface of the substrate, but the so-formed material is combined with the side-to-side spacing between the individual sections of the scrubbing material. Scrubiness properties can be imparted to the wiped substrate even more and possibly more depending on the extent to which it extends from or beyond the substrate surface. The printed texture layer 14 of the present invention provides both of these scrubiness requirements and meets it uniquely.

  As a further illustration, the texture layer 14 preferably defines a pattern on the substrate surface 16 that includes a plurality of separate sections (eg, various line-like sections shown in FIG. 1 and generally referenced 20a, 20b). To do. During the scrubbing application, a user (not shown) will typically place the scrubbing wipe article 10 so that the texture layer 14 faces the surface to be cleaned. An example of this orientation is provided in FIG. 3 where the scrubbing wipe article 10 is placed to clean the surface 30. As should be appreciated, the surface 30 to be cleaned is application specific and can be relatively hard (eg, a table top or cooking pot) or relatively soft (eg, human skin). In any case, the surface 30 to be cleaned may have a mass 32 that is undesirably stuck to it. Again, the mass 32 is specific to a particular cleaning application, but includes substances such as dust, dry food, dry blood, and the like. The scrubbing wipe article 10 of the present invention facilitates scrubbing removal of the mass 32 as the user repeatedly moves the texture layer 14 (or a portion thereof) back and forth across the mass 32. Each section of the texture layer 14 (eg, sections 20a, 20b) must be stiff enough to either scrape the mass 32 or completely remove it during the scrubbing movement. Further, the texture layer 14 must extend a significant distance from the substrate surface 16 to ensure close surface interaction with the mass 32 not only along the outermost surface 40 but also along the side surface 42 as well. I must. In particular, most cleaning wipes that incorporate blown fiber “scrubbing” or texture layers provide only minimal thickness or elongation with respect to the substrate surface, and probably produce less scrubiness properties than desired. In addition, the separate sections provided by the texture layer 14 of the present invention (eg, sections 20a, 20b) are tightly packed between the mass 32 and the sidewall 42 of the particular texture layer section 20a, 20b throughout the cleaning operation. It is preferred that they be spaced sufficiently apart from one another to ensure contact. This is easily accomplished by the printing techniques made available by the texture layer matrix of the present invention as described below.

With the above preferred performance parameters in mind, the nonwoven substrate 12 can take a wide variety of forms that provide a variety of different desirable properties. Various materials and manufacturing techniques are described below. However, regardless of the exact configuration, the nonwoven substrate 12 is very useful for handling by a user who otherwise uses the wiping article 10 for cleaning purposes. In particular, consumers prefer that cleaning wipes, such as the wiping article 10 of the present invention, be relatively flexible or not stiff. This desired property allows the user to easily fold, squeeze, or otherwise manipulate the wiping article 10 in the manner most appropriate for a particular cleaning job. A relatively unbent or stiff substrate will greatly hinder this desired form of use. The desired flexibility of the substrate 12 is best described in terms of its dry basis weight. The nonwoven substrate 12 of the present invention has a dry basis weight of less than about 300 g / m ² but preferably greater than about 30 g / m ² . In a more preferred embodiment, the nonwoven substrate 12 has a dry basis weight of less than about 200 g / m ² . Alternatively, the flexibility of the nonwoven substrate 12 can be expressed in terms of drape. “Drapability” is defined as the inherent ability to conform to an irregular or uneven surface. Drapability or “drape” is measured using the INDA standard for “Handle-0-Meter Stiffness of Nonwoven Fabrics” IST 90.3 (95). With this in mind, the nonwoven substrate 12 preferably has a drape value of less than about 250.

  The nonwoven substrate 12 can be formed from a variety of materials and in a variety of ways selected to provide desired properties such as extensibility, elasticity, etc. in addition to the required flexibility. Most generally, the substrate 12 consists of individual fibers that are entangled (and optionally joined) to each other in the desired manner. The fibers are preferably synthetic or manufactured, but may include natural materials such as wood pulp fibers. As used herein, the term “fiber” includes infinite length fibers (eg, filaments) and discontinuous length fibers (eg, staple fibers). The fibers used in connection with the nonwoven substrate 12 may be multicomponent fibers. The term “multicomponent fiber” refers to a structure having at least two distinct longitudinally identical spreads, as opposed to blends whose regions tend to be dispersed, random, or unstructured Means a fiber having an activated polymer region in the fiber cross section. Thus, the distinct regions may be formed of polymers from different polymer classes (eg, nylon and polypropylene) or are of the same polymer class (eg, nylon) but differ in their properties or characteristics It may be formed of a polymer. Thus, the term “multicomponent fiber” includes concentric and eccentric sheath-fiber structures, symmetric and asymmetric side-by-side fiber structures, sea-island fiber structures, pi-wedge fiber structures, and hollow fibers of these structures. Is intended to be not limited thereto.

In addition to the availability of a wide variety of different types of fibers useful for the nonwoven substrate 12, the techniques for joining the fibers together are also extensive. In general terms, suitable methods of manufacturing the nonwoven substrate 12 that may be used in connection with the present invention include spunbond, blown microfiber (BMF), thermal bonding, wet laid, airlaid, resin bonded, spanned. Including, but not limited to, laced and ultrasonic bonding. In a preferred embodiment, the substrate 12 is spunlaced according to known spunlace processing techniques using sized fibers. In this most preferred manufacturing technique, a preferred construction of the nonwoven substrate 12 is a blend of 50-60 g / m ² of 50/50 wt% 1.5 denier polyester and 1.5 denier rayon. The substrate 12 is first sown as is known in the art and then entangled by a high pressure water jet. The preferred one-spun lace technique eliminates the need for a thermal resin bonding component, so that the resulting nonwoven substrate can contain virtually any type of chemical solution (ie, anionic, cationic, or neutral). ) Can be loaded.

  Although the nonwoven substrate 12 is depicted as a single layer structure in the cross-sectional view of FIG. 2, it should be understood that the nonwoven substrate 12 may be of a single layer or a multilayer structure. It will be appreciated that when a multilayer structure is used, the various layers may have the same or different properties, structures, etc., as is known in the art. For example, in an alternative embodiment, the nonwoven substrate 12 is constructed with a first layer of 1.5 denier rayon and a second layer of 32 denier polypropylene. This alternative structure provides a relatively soft substrate so that the resulting wiping article 10 is useful for applications that clean the user's skin, similar to a face cleaning wipe.

  The texture layer 14 is an abrasive non-crosslinked resin base material as described above. As described in more detail below, the exact composition of the texture layer 14 can vary depending on the desired final performance characteristics. For this purpose, the texture layer matrix is first formulated and then printed onto the substrate 12. This matrix consists of a selected resin and may contain additional components such as minerals, fillers, colorants, thickeners and the like. However, regardless of the exact composition, the selected resin provides the desired scrubiness properties to the wiping article 10 by fusing the printed matrix (which otherwise achieves bonding of the matrix to the substrate 12). . In other words, other added bead materials are required to achieve and maintain a useful outer extension of the texture layer with respect to the substrate surface (thus providing a stiff surface that can contact and achieve scrubbing). Unlike the technology, the resin associated with the texture layer 14 of the present invention extends to a substantial extent independently from the surface of the substrate 12 immediately after printing thereon. As a basis for judgment, the resin component is defined as “non-crosslinked” when referring to the texture layer matrix (ie, before printing), and “uncrosslinked” when referring to the printed fused texture layer 14. Is defined. This definitional distinction more closely reflects that the matrix of the present invention does not require a cross-linking agent and that a useful texture layer 14 is provided without a cross-linked resin.

  The non-crosslinked abrasive resin component of the texture layer 14 can take a variety of forms and may or may not be thermoplastic. Importantly, however, the resin is of a type that does not require crosslinking to fuse the next print. With this in mind, the abrasive non-crosslinked resin can be a polyacrylate, modified polyacrylate, polyurethane, polyvinyl acetate, copolyamide, copolyester, or phenolic resin. Acceptable resin materials are, for example, under the trade name “BB-077 phenolic resin (Phenolic Resin)” from Nest Resins Canada of Missuga, Ontario, Canada. Air Products (Hybridur) (such as Hybridurd 540, 560, 570, or 580), AirFlex Series, and AirBond Series, Chicago, Illinois ( From Mass Products, Inc., of Chicago, Illinois) under the trade name "Zeneca A1052" Sumter, South Carolina from the Zeneca Resins of Wilmington, Massachusetts, California under the trade name “P, VP or D-series” as copolyester or copolyamide dispersions as well as other latex and polyurethanes Available from EMS-Griltex of Sumter, South Carolina. As described below, the weight percentage of the specific resin and texture layer matrix basis can be fine tuned to meet the desired end use constraints. However, the selected resin only partially penetrates into the nonwoven substrate 12 when printed on it (i.e. does not soak into the substrate 12 or wets the substrate 12 completely), and various drying Characterized as flowable in matrix form so that it will fuse upon exposure to conditions. In this connection, thermal energy is required when copolyesters or copolyamides are used. Furthermore, the resin component of the texture layer 14 is preferably nonionic. Some of the exemplary acceptable resins listed above are nonionic. The preferred non-ionic nature of the resin associated with the texture layer 14 of the present invention facilitates the use of virtually any form of chemical solution if so desired.

In a preferred embodiment, the texture layer 14 optionally further comprises a particulate additive for hardness enhancement. For this purpose and as described in more detail below, the inventive scrubbing wipe article 10 is useful in a wide variety of potential applications with different scrubbing requirements. For some applications, it is desirable that the scrubbing wipe article 10, and in particular the texture layer 14, be more or less abrasive than others. Although the resin component of the texture layer 14 described above provides the article 10 independently with greater scrubiness properties than other available wipes, this scrubberiness property can be further enhanced by the addition of particulate components. . With this in mind, a wide variety of minerals or fillers as known in the art can be used. Useful minerals include Al ₂ O ₃ , “Minex” (available from The Cary Co. of Addison, Illinois), SiO ₂ , TiO _{2, and the} like. Exemplary fillers include CaCO ₃ , talc, and the like. When used, the particulate component additive comprises less than 70% by weight of the texture layer 14, more preferably less than 50% by weight, and most preferably less than 30% by weight. In addition, the particulate component preferably consists of inorganic hard small particles. For example, the “Minex” mineral particulate component has an average particle size of 2 microns and a Knoop hardness of about 560. Of course, other particle size and hardness values may also be useful. The preferred inorganic nature of the particulate component, together with the preferred non-ionic resin component, allows the resulting texture layer 14 to be easily used with any type of chemical solution.

  The texture layer 14 can further include a colorant or pigment additive to impart a desired aesthetic appeal to the wiping article 10. Suitable colorants are well known in the art and are sold, for example, under the trade name “Sunsparse”, available from Sun Chemical Corp. of Amelia, Ohio, Ohio. Including products. Other colorants as known in the art are equally acceptable, but preferably account for less than 1% by weight of the texture layer matrix.

  The texture layer matrix can include additional components such as thickeners to achieve the most desirable viscosity for the particular printing technique used and the speed of the production line. In this regard, suitable thickeners are known in the art and are available under the trade designation “Rheolate 255” from Methylcellulose and Rheox, Inc. of Hightown, New Jersey. Material. In particular, thickeners may be unnecessary depending on the resin and printing technique selected, but when used, the thickener preferably accounts for less than approximately 5% by weight of the texture layer matrix.

Finally, and as described above, the scrubbing wipe article 10 of the present invention can be used “dry” or loaded with a chemical solution. The term “loaded” relates to the chemical solution being absorbed by the nonwoven substrate 12 before being delivered to the user. During use, the chemical solution is released from the nonwoven substrate 12 as the user wipes the scrubbing wipe article 10 across the surface. Due to the preferred nonionic nature of the texture layer 14, water, quaternary ammonium salt solution, Lauricidin ^™ -based antibacterial agent, alcohol-based antibacterial agent, citrus base cleaner, solvent-based cleaner, cream brightener, anionic cleaner, Virtually any desired chemical solution can be loaded, including amine oxides and the like. In other words, when used, the chemical solution can be anionic, cationic, or neutral.

  The manufacture or formation of the scrubbing wipe article 10 of the present invention generally involves the steps of formulating a suitable texture layer matrix, printing the matrix onto the substrate 12, and then fusing the printed matrix. Joining the matrix to the substrate 12, thereby providing the texture layer 14. Various techniques for the actual printing of the matrix are described below. Importantly, however, the texture layer matrix is formulated so that the resin component does not crosslink as part of the fusing process. In other words, the fusion of the texture layer 14 does not involve “curing” in the traditional sense. Instead, the texture layer 14 is fused by the release of water, such as by drying and / or exposure to infrared light. This represents a clear advantage over other scrubbing wipe article forming techniques where a very long cure period (approximately 28 days) is required to achieve sufficient hardness values.

  The texture layer matrix can be printed on the substrate 12 using various known techniques such as screen printing, gravure printing, flexographic printing, and the like. Some of these techniques are described in more detail below. In one preferred embodiment, the printing operation is performed in-line with the nonwoven substrate 12 forming operation. In this regard, it will be recalled that the substrate 12 can be formed by a variety of known techniques including spunlace, wet raid, and the like. In some of these techniques, a selected web of fibrous material is rolled and then entangled by a high pressure water jet. The resulting substrate is then dried. In this regard, other available scrubbing wipe products (whether by printing or BMF) require that the substrate be completely dry before applying the texture layer. The articles and methods of the present invention are not so limited. Rather, the texture layer matrix can be printed onto the nonwoven substrate 12 while the substrate 12 is still wet. Next, subsequent drying of the nonwoven substrate 12 and the texture layer 14 can occur simultaneously, thereby eliminating manufacturing steps and greatly streamlining the overall processing. This preferred in-line processing is illustrated in a highly simplified block form in FIG. The substrate 12 is first formed (by the card device 52) as a continuous squeezed web 50 and then entangled by a high pressure water sprayer 54 to define a nonwoven substrate web 56. The texture layer matrix 14 (which is greatly exaggerated in FIG. 4) is printed on the web substrate 56 by a printer 58 (schematically illustrated in FIG. 4 including a roll type printing device). Next, both the texture layer 14 on which the oven 60 is printed and the substrate 12 are dried. Finally, the printed substrate can be wound up and stored for subsequent conversion or immediately converted into individual articles 10. Alternatively, the articles 10 can be formed in-line as described, but can be printed as individual articles 10. In addition, conventional processing methodologies can be used.

  In one preferred embodiment, the texture layer matrix is printed onto the nonwoven substrate 12 by conventional screen printing. In this technique, an imaging sheet is formed to define a desired printed pattern, such as by stamping or cutting the desired pattern into the sheet metal. The imaging sheet is then placed on the nonwoven substrate 12, particularly the desired surface 16,18. A texture layer matrix is then fed along the opposite side of the imaging sheet and pushed through the defined pattern onto the nonwoven substrate 12 to form the desired texture layer 14 pattern. The texture layer 14 is then fused in a suitable manner, such as by placing it in a relatively cool oven (approximately 150 ° C. for less than about 2 minutes), and thus bonded to the substrate 12. Alternatively, texture layer 14 is exposed to infrared light for a short period (less than about 2 minutes). In any case, the texture layer 14 is fused and thus bonded to the substrate 12, and the scrubbing wipe article 10 is ready for use.

  Alternatively, gravure printing technology can be used. As is known in the art, the texture layer matrix is fed onto the top surface of a gravure roll that otherwise forms indentations defining the desired pattern. A doctor blade is then used to push the matrix into the recess. The texture layer matrix is then transferred to the nonwoven substrate 12 by passing the substrate 12 through a nip point defined by a gravure roll and a separate rubber roll. This technique can provide the texture layer 14 with a finely replicated design or pattern. In any event, after printing, the texture layer 14 is fused and bonded to the substrate 12 as previously described.

  Alternatively, flexographic printing can be used in which the feed roll feeds the texture layer matrix to the printing plate cylinder via an intermediate anilox roll that controls the amount of matrix feed. The nonwoven substrate 12 is then contacted with a printing plate cylinder, at which time the texture layer matrix is transferred or printed from the printing plate cylinder to the substrate 12.

  Regardless of the specific printing technique, the resulting substrate 12 / texture layer 14 is immediately available for use in scrubbing and cleaning applications. Upon printing of the matrix and subsequent fusion (and thus bonding to the substrate 12), the texture layer 14 is at least 50 with respect to the substrate surface on which the texture layer 14 is printed (ie substrate surface 16 in FIG. 1). It is characterized by an extended micron distance (represented as “X” in FIG. 2). More preferably, the texture layer 14 extends at least 100 microns, even more preferably at least 150 microns, from the corresponding substrate surface. In particular, texture layer 14 elongation values of at least 50 microns are not found with known lightweight scrubbing wipes and provide excellent scrubbing capabilities. Alternatively, elongation values of less than 50 microns can also be provided by the present invention and may be appropriate for certain end uses. Conversely, elongation values in excess of 400 microns can also be achieved. Indeed, extension values in excess of 1000 microns are available for the texture layer 14 of the present invention and may be useful in certain applications.

  As previously described, the texture layer 14 covers less than the entire nonwoven substrate surface on which it is printed (ie, the surface 16 of FIG. 2) and includes two or more separate sections. The pattern is preferably printed. In this connection, a wide variety of patterns can be printed. For example, the pattern can consist of a plurality of separate lines as shown in FIG. Alternatively, the lines can be connected to each other. In yet another alternative embodiment, and with further reference to FIG. 5, the printed texture layer consists of a plurality of discrete dots or islands. In addition, other desirable pattern components can be formed, such as company logos. Alternatively, a more randomly distributed texture layer section can be printed. In short, by printing the texture layer 14, it is possible to obtain substantially any pattern with good definition. By printing the texture layer 14 preferably in a separate pattern, the drapeability or “hand” of the nonwoven substrate 12 is not significantly impaired.

  Regardless of the exact dimensions and pattern of the texture layer 14, the scrubbing wipe article 10 of the present invention provides a significant improvement over previous consumer scrubbing wipes in terms of enhanced scrubiness and ease of manufacture. An exemplary texture layer 14 composition is provided below and illustrates the ability to fine tune the texture layer matrix to meet specific end use needs. In other words, a lesser degree of scrubiness may be desirable for certain end use applications. To meet these needs, the components and / or weight percent amounts provided by the texture layer matrix formulation can be easily varied but are encompassed within the scope of the present invention.

Example 1
A scrubbing wipe according to the present invention using a 50/50 wt.% 1.5 denier polyester and 1.5 denier rayon nonwoven substrate formed by a spunlace operation which is web rolled and then entangled by a high pressure water jet Articles were manufactured. The texture layer matrix was then fused by screen printing onto the substrate and then drying in an oven at 150 ° C. with a residence time of less than 2 minutes. The base nonwoven substrate before printing was approximately 60 g / m ² and approximately 10 mils thick, and after printing and drying, the resulting scrubbing wipe article was approximately 70 g / m ² and approximately 20 mils thick. (In the region where the texture layer is formed). The texture layer matrix formulation of Example 1 is shown in Table 1 below.

Example 2
A scrubbing wipe article similar to that described in Example 1 was made using different texture layer matrices printed on the same nonwoven substrate. The texture layer matrix of Example 2 consisted of the components listed in Table 2.

Example 3
A scrubbing wipe article similar to that described in Examples 1 and 2 was made using different texture layer matrices printed on the same nonwoven substrate. The texture layer matrix of Example 3 consisted of the components listed in Table 3.

Example 4
A scrubbing wipe article similar to that described in Examples 1-3 was produced using different texture layer matrices printed on the same nonwoven substrate. The texture layer matrix of Example 4 consisted of the components listed in Table 4.

Example 5
A scrubbing wipe article similar to that described in Examples 1-4 was produced using different texture layer matrices printed on the same nonwoven substrate. The texture layer matrix of Example 5 consisted of the components listed in Table 5.

Example 6
A scrubbing wipe article similar to that described in Examples 1-5 was produced using different texture layer matrices printed on the same nonwoven substrate. The texture layer matrix of Example 6 consisted of the components listed in Table 6.

Example 7
A scrubbing wipe article similar to that described in Examples 1-6 was made using different texture layer matrices printed on the same nonwoven substrate. The texture layer matrix of Example 7 consisted of the components listed in Table 7.

  In particular, the EMS-Griltex paste of Example 7 allows printing and subsequent formation of a raised texture layer from the solution in conjunction with an aerated oven. This could not be achieved with a powder resin.

  Each of the above Examples 1-7 produced an acceptable scrubbing wipe article that the printed texture layer gave enhanced scrubberiness properties and could clean the surface for various applications. As a basis for judgment, it is possible to characterize “scrubbiness” as a function of the amount of dry food soil removed from the surface by the scrubbing wipe article when moistened and applied in a scrubbing manner. is there. An example of a test methodology is R.A. D. S. Coat a 4 inch diameter stainless steel disc (or “panel”) with barbecue sauce using a standard # 60 coating rod (Coating Rod). As such, the coated panel is baked at 200 ° F. for 1.5 hours. The coating / baking process is then repeated two more times for a total of 3 coats on the panel and approximately 2.4 grams of food soil. To measure the scrubberness value, note the initial weight of the manufactured panel. Wet a sample of the wipe article in question with water to approximately 300% of its initial weight ([final weight-initial weight] / initial weight). The sample and coated panel are then placed in a suitable device that can reproduce the scrubbing action. After scrubbing application, the panel is reweighed and the difference in panel weight (initial weight-final weight) indicates the scrubbing value of the scrubbing wipe.

In connection with specific Sukurabinesu values listed below, approximately every 8-inch × 8 inches sample wipe 3.75 inch disks one surface of Scotch Brite ^TM carpet cleaning floor pad ^{(ScotchBrite TM Carpet Cleaning Floor Pad)} , Attached to the upper turntable of a Schiefer Ablation Tester (available from Frazier Precision Instrument Co. of Silver Spring, Maryland), Silver Spring, Maryland. The coated panel (whose initial weight was recorded) was placed in a metal holder on the bottom turntable. A 2 pound weight was placed on top of the Schiefer head. The head was lowered onto the bottom disk and the machine was moved 25 turns. The coated panel was removed and dried in an oven at 200 ° F. for 15 minutes and reweighed. The scrubiness value was defined as the difference between the initial weight and the final weight of the coated panel.

  Using the test procedure described above, the nonwoven substrate used in each of Examples 1-7 had a scrubiness value of 0.5 grams. The scrubbing wipe article according to Example 1 has a scrubiness value of 0.76 grams, the scrubbing wipe article according to Example 2 has a scrubiness value of 0.84 grams, and the scrubbing wipes according to Example 7 The article had a scrubiness value of 0.72 grams. Although no scrubiness values were collected according to the above test procedure for Examples 3-6, manual inspection (visual and tactile) of each scrubbing wipe article was provided by the base nonwoven substrate alone A unique scrubbery characteristic well above that was clarified. In any event, the texture layer of the present invention increases the scrubiness value otherwise provided by the nonwoven substrate alone by at least 0.1 grams.

  In addition to scrubiness, some drape properties of the above examples were also analyzed to confirm that the texture layer of the present invention does not clearly affect the desired drape properties. For this purpose, using the INDA standard for “Nonwoven Handle-0-Meter Stiffness” IST 90.3 (95), the following deformation (sample size tested is 100 mm × 100 mm, slot width Was 100 mm) and the drape was measured using a handle-0-meter model 211-300. The load cell was 1000 grams. The standardized drape value for the nonwoven substrates used in Examples 1-7 was approximately 40.8 (standardized to the heaviest basis weight). A scrubbing wipe article printed with a dot pattern (similar to the pattern of FIG. 5) according to Example 2 above had a standardized drape value of approximately 39.9 weight grams. The scrubbing wipe article printed in a line pattern (similar to the pattern of FIG. 1) according to Example 2 above had a standardized drape value of 90.2 weight grams. A scrubbing wipe article printed with a dot pattern (similar to the pattern of FIG. 5) according to Example 7 above had a standardized drape value of approximately 39.4 weight grams.

  As demonstrated by the above examples, the texture layer matrix can be fine tuned to improve the scrubbing ability of the resulting article 10 and to provide the desired scrubbing value for the resulting scrubbing wipe article 10. Regardless of the exact formulation, the selected abrasive non-crosslinked resin component independently imparts considerable scrubiness to the wipe article 10 when bonded to the substrate 12. Additional matrix components can be added to increase the hardness of the resulting texture layer 14, the pigment or color of the texture layer 14, and / or the viscosity of the texture layer matrix. After fusing, the texture layer matrix comprises about 30% to 100% non-crosslinked resin, 0% to 70% particulate mineral or filler, 0% to 5% colorant, and 0% It consists of a thickener of 5% to 5% by weight.

  Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.

1 is a plan view of an exemplary consumer scrubbing wipe article according to the present invention. FIG. It is the expanded sectional view of the part along line 2-2 of the article | item of FIG. FIG. 3 is an enlarged cross-sectional view of the article portion of FIG. 2 applied to the surface. FIG. 6 is a simplified block diagram of a manufacturing method according to an embodiment of the present invention. FIG. 6 is a plan view of an alternative embodiment scrubbing wipe article according to the present invention.

Claims (51)

A nonwoven substrate having a dry basis weight of less than about 300 g / m ² ;
A consumer scrubbing wipe article comprising a non-crosslinked abrasive resin-based texture layer printed onto at least one surface of the substrate such that when fused, the texture layer extends at least 50 microns outward beyond the substrate surface. An article in which the texture layer covers less than the entire surface of the substrate. The article of claim 1, wherein the nonwoven substrate has a dry basis weight greater than about 30 g / m ² .   The article of claim 1, wherein the nonwoven substrate is characterized by a drape value of less than 250.   The article of claim 1, wherein the nonwoven substrate is characterized by the absence of wood pulp fibers.   The article of claim 1, wherein the nonwoven substrate is characterized by the absence of a thermal bonding component.   The article of claim 1, wherein the texture layer extends at least 100 microns outward beyond the substrate surface.   The article of claim 6, wherein the texture layer extends at least 400 microns outward beyond the substrate surface.   The article of claim 1, wherein the texture layer comprises a resin characterized as independently providing scrubberiness properties to the article when fused.   The article of claim 8, wherein the resin is a polyacrylate.   The article of claim 8, wherein the resin is a modified polyacrylate.   The article of claim 8, wherein the resin is polyurethane.   The article of claim 8, wherein the resin is polyvinyl acetate.   The article of claim 8, wherein the resin is a copolyamide.   The article of claim 8, wherein the resin is a copolyester.   The article of claim 8, wherein the resin is a phenolic resin.   The article of claim 8, wherein the resin is non-ionic.   The article of claim 8, wherein the texture layer further comprises a particulate component.   The article of claim 17, wherein the particulate component is selected from the group consisting of fillers and minerals.   The article according to claim 17, wherein the particulate component is an inorganic substance.   The article of claim 17, wherein after coalescence, the particulate component comprises less than 70% by weight of the texture layer.   21. The article of claim 20, wherein after coalescence, the particulate component comprises less than 30% by weight of the texture layer.   The article of claim 1, wherein the texture layer comprises a plurality of randomly distributed texturing.   The article of claim 1, wherein the texture layer defines a pattern.   24. The article of claim 23, wherein the pattern comprises a plurality of discrete segments.   25. The article of claim 24, wherein the separate segments comprise a series of unconnected lines.   The article of claim 1, wherein the texture layer increases the scrubiness value of the nonwoven substrate by at least 0.1 grams.   The article of claim 1, wherein the texture layer is non-ionic.   The article of claim 1, wherein the texture layer is anionic.   The article of claim 1, wherein the texture layer is cationic.   The article of claim 1, further comprising a chemical solution absorbed into the nonwoven substrate.   32. The article of claim 30, wherein the chemical solution is cationic.   32. The article of claim 30, wherein the chemical solution is anionic.   32. The article of claim 30, wherein the chemical solution is neutral. Providing a nonwoven substrate having a dry basis weight of less than about 300 g / m ² defining first and second opposing surfaces;
Providing an abrasive resin base matrix;
Printing the matrix onto a first surface of the nonwoven substrate, the printed matrix covering less than the entirety of the first surface;
Fusing the printed matrix to produce a texture layer that imparts scrubberiness properties, wherein the texture layer is created without cross-linking of the matrix resin;
A method of making a consumer scrubbing wipe article that extends at least 50 microns outward beyond the first surface when the texture layer is fused.   35. The method of claim 34, wherein the fused texture layer extends at least 100 microns outward beyond the first surface.   36. The method of claim 35, wherein the fused texture layer extends at least 400 microns outward beyond the first surface.   35. A method according to claim 34, characterized in that the manufacturing method is absent a curing step following the fusion of the printed matrix.   Providing an abrasive resin base matrix includes applying the matrix to include a resin applied to the first layer and adapted to extend outwardly beyond the first layer independent of other matrix components when fused. 35. The method of claim 34, comprising forming. The step of forming the abrasive resin base matrix
Determining a desired abrasiveness of the texture layer after fusing,
39. The method of claim 38, comprising selecting a resin component for the matrix based on the desired abrasiveness.   40. The method of claim 39, wherein forming an abrasive resin base matrix further comprises determining an amount of a selected resin included in the matrix based on the desired polishability.   39. The method of claim 38, wherein the step of forming the matrix further comprises combining with the resin a particulate component that comprises less than 30% by weight of the resulting matrix.   35. The method of claim 34, wherein the substrate is dry immediately prior to the printing step.   35. The method of claim 34, wherein the substrate is wet immediately prior to the printing step.   Providing the nonwoven substrate includes entanglement of the substrate fibers with high pressure water spray, and further providing the nonwoven substrate and printing the matrix onto the nonwoven substrate; 44. The method of claim 43, wherein is performed inline.   35. The method of claim 34, wherein printing the matrix onto the nonwoven substrate comprises screen printing the matrix onto the nonwoven substrate.   35. The method of claim 34, wherein printing the matrix onto the nonwoven substrate comprises gravure printing the matrix onto the nonwoven substrate.   35. The method of claim 34, wherein printing the matrix onto the nonwoven substrate comprises flexographic printing the matrix onto the nonwoven substrate.   35. The method of claim 34, wherein the matrix is pattern printed onto the nonwoven substrate.   49. The method of claim 48, wherein the pattern comprises a plurality of repeated discrete lines.   35. The method of claim 34, wherein the matrix is printed onto a nonwoven substrate to define randomly distributed texturing.   35. The method of claim 34, further comprising absorbing a chemical solution into the nonwoven substrate.

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